New High flow lower manifold
Thread Starter
Senior Member
Joined: 07-10-07
Posts: 503
Likes: 0
From: Toronto
New High flow lower manifold
So from popular demand we have decided to continue with the project with the help of the community.
Here is the break down.
1. Last thread:
https://www.cobaltss.net/forums/2-0l-lsj-performance-tech-47/feeler-ported-m62-lower-intake-manifold-73029/
NOTE: this will only include the lower manifold, NO PORTED SUPERCHARGER, for that portion just get a TS or TVS.
2. Design:
What we want to do is machine off the back portion, insert a copper/tin core inside and build up the back with proper runners. This way the SC will fit perfectly and the lower manifold will be mounted flat. We know from experience that any imperfection in the mounting of the SC can cause it to seize.
cores will be something like this:
back of manifold with runners will be something like this (combination):
The supercharger placement will be stock, the look will be like stock. Basically everything modified will be below and behind the manifold. Once we see interest we will do a CAD model of the design.
We will estimated 20HP - 100HP gains depending on other mods.
3. Cost to produce (approx):
machining of the manifold $100-150
new core $200-250
header flange $50-100
runners $40-60
welding and extras $100-150
parts for testing $1000/20 = $50
so around $540-760
4. To get this project moving we have asked 20 member to put down a $100 deposit each. These 20 will get the manifold at cost as stated. We will purchase 2 manifolds to start with and do core exchanges from there so no one experiences any down time.
5. Timeline for first manifold to be completed:
a) purchasing of parts - 1 week
b) machining of manifold - 1 day
c) new cored manufacturing - 2 weeks
d) welding - 2 days
6. List:
1. Rebel
2. lewisb13
3. burntorange
4. JR Racing
5. Shaun927
6. ls1fbody
7. infernica
8. Gabi
9. paul1588
10. AcesNEights
11. nuttzzy
12. Altiery54
13. bolus
14. victory_red_SS (for his DD
)
Please PM us to be added to the list
Some Preliminary CAD work:
This is the basics of where we want to go with the project.
Again these are just preliminary drawings, let's not get into details of "why do the runners cross?" of course the final version will not. This is just to help everyone vision the final product
Here is the break down.
1. Last thread:
https://www.cobaltss.net/forums/2-0l-lsj-performance-tech-47/feeler-ported-m62-lower-intake-manifold-73029/
NOTE: this will only include the lower manifold, NO PORTED SUPERCHARGER, for that portion just get a TS or TVS.
2. Design:
What we want to do is machine off the back portion, insert a copper/tin core inside and build up the back with proper runners. This way the SC will fit perfectly and the lower manifold will be mounted flat. We know from experience that any imperfection in the mounting of the SC can cause it to seize.
cores will be something like this:
back of manifold with runners will be something like this (combination):
The supercharger placement will be stock, the look will be like stock. Basically everything modified will be below and behind the manifold. Once we see interest we will do a CAD model of the design.
We will estimated 20HP - 100HP gains depending on other mods.
3. Cost to produce (approx):
machining of the manifold $100-150
new core $200-250
header flange $50-100
runners $40-60
welding and extras $100-150
parts for testing $1000/20 = $50
so around $540-760
4. To get this project moving we have asked 20 member to put down a $100 deposit each. These 20 will get the manifold at cost as stated. We will purchase 2 manifolds to start with and do core exchanges from there so no one experiences any down time.
5. Timeline for first manifold to be completed:
a) purchasing of parts - 1 week
b) machining of manifold - 1 day
c) new cored manufacturing - 2 weeks
d) welding - 2 days
6. List:
1. Rebel
2. lewisb13
3. burntorange
4. JR Racing
5. Shaun927
6. ls1fbody
7. infernica
8. Gabi
9. paul1588
10. AcesNEights
11. nuttzzy
12. Altiery54
13. bolus
14. victory_red_SS (for his DD
)Please PM us to be added to the list
Some Preliminary CAD work:
This is the basics of where we want to go with the project.
Again these are just preliminary drawings, let's not get into details of "why do the runners cross?" of course the final version will not. This is just to help everyone vision the final product
Last edited by Eng@RebelAutoWorxs; Sep 2, 2008 at 10:10 PM.
Not a Sebring
Joined: 02-22-07
Posts: 12,863
Likes: 2
From: Northern VA
Now we just need someone to R&D a new manifold for us 2.4 guys. Or better yet, how about a manifold + big bore TB package for the LE5. I'd be alllll over that if someone ever made on (hint hint) 
question how is the right side of the new manifold going to be, for those of us with a dual pass setup on already, is it a dual pass setup also that we can just slide the hoses right onto
Also will this new design have any sort of added cooling properties because if it doesnt regardless of power increase it wont help alot of us
Also will this new design have any sort of added cooling properties because if it doesnt regardless of power increase it wont help alot of us
Senior Member
Joined: 07-30-07
Posts: 2,220
Likes: 0
From: Home: Utica, MI Current Location: Mobile, Alabama
Cmon guys, think about this. Youll have a one off mod! How many of us have been complaining that the intake mani is the bottleneck? Lets get some R&D money together!
